slab track nff system

8/10/2019 Slab Track NFF System

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Your bridge togreater economy.The New Slab TrackNFF System.

ThyssenKrupp GfT Gleistechnik


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Your bridge to greater economy.The New Slab Track NFF System.

1 NFF System in a bend

2 Exploded installation drawing

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crossfall +100 mm

horizontal

So, what are the new features? In contrast to conventional slab,

which depend on a full surface bedding, the NFF System is a

bridge-type construction with a superstructure for rail traffic. The

load demolition must not directly take place underneath the carri-

ageway slab, but can be introduced by means of drill or pressure-

grouted piles directly in (more deeply lying) load-carrying gound

layers. This innovation renders the soil exchange that is normally

required redundant, thus leading to tremendous cost savings.

Our new development the New Slab TrackNFF System has been undergoing thoroughtesting on a test track since 2008. And theresults have been impressive. A licence wasissued for it by the Federal Department ofRails at Aug. 12th. 2010. We are the only ma-nufacturer of the system and as such we cansupply a patented solution throughout Europefor tracks and track sections which are affectedby unfavourable or difficult soil types.


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Step by step innovation.System and installation.

System

The NFF System normally consists of deep

foundations as individual foundations, which have a

positive connection to rigid portal systems. Longitudinal

bearer units (LTE) in the form of prefabricated concrete

components are installed on these in the correct position

by means of a positive connection. These LTEs consist

of two longitudinal sleepers with three lateral connections

level with the rigid portal systems so as to form a pre-

fabricated rail support grid. The rail fasteners and

segment rails are already mounted in the correct posi-

tion on the longitudinal sleepers.

The NFF System is suitable for use with all types of

track such as gradients, bends, superelevations and

crossings. The rails are fastened using the Krupp ECF

system from ThyssenKrupp GfT Gleistechnik. This makes

subsequent height corrections of -4 mm to +26 mm

and side corrections of 10 mm possible. A rail gradient

of 1:40 or 1:20, etc. can be achieved using different rib

plates, while the requisite elasticity is provided by an

elastic pad beneath the rib plate.

Installation

The New Slab Track NFF System is manufactured

using the following procedures:

Installation of the deep foundations during

breaks in service either overnight or at weekends

Concrete curing during normal operations, extension

of the sleepers and rails, bedding of the ballast

Installation of the rigid portal systems by means of

vacuum, precise adjustment and concreting of the

openings in the rigid portal systems for connection

to the threaded rods in the micropiles

Alignment and installation of the longitudinal bearerunits, prestressing with the rigid portal systems

Replacement of the segment rails with long rails

Reinstallation of the ballast material

Inspection of the rail position, concreting the

clamping channel

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1 Drill (for producing the deep foundations)

2 Drilled piles with sub-base course

3 Rigid portal system with elastomer mat

4 Swinging the LTEs into position

5 Measuring the LTEs

6 Rigid portal system with connected

reinforcement

7 Rigid portal system with thrust

mandrels

8 Rail installation

9 Rail installation; ballasting

10 Transition between ballast and

NFF System

11 Finished, ballasted (not padded)

NFF System section

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1 Passing the measurement

equipment zone2 Krupp ECF rail fastener

3 A fully laden train passing

4 View of finished NFF System route

A good drive in every respect.Benefits.

1 2

crossfall+100 mm

15 mm

15 mm

15 mm

crossfall+100 mm

axis

ofrail

L=10.80

Rmin= 600

An integral component of any approval involves testing

under normal operating conditions. For this purpose weset up a test track on the factory premises of Rheinkalk

AG in Wlfrath in late summer 2008. Here the existing

ballast track, approximately 120 m in length, was con-

verted to the NFF System.

The non-homogeneity of the soil with its wildly fluctu-

ating (bearing) properties made it ideal for trying out the

system. Axle loads up to 22.5 metric tonnes and train

loads up to approx. 1800 metric tonnes were brought to

bear here meaning a total of no less that 2,000,000

metric tonnes by mid-2010. Measurements taken by

the University of Duisburg-Essen showed that over theentire period no major settlement or sagging had taken

place.

The result is the issue of an approval from the Eisen-

bahn Bundesamt (the Federal Railway Authority of

Germany). Excellent quality!


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Economic advantages

No expensive foundation soil work is required during

the earthworks. The loads are directed through the

deep foundations. This means that even existing

destabilized slopes can be upgraded.

There is generally no waste disposal work because

the existing ballast can be reinstalled in and next to

the track grid.

Mounting the rail on innovative longitudinal sleepers

means reduced vibration. In turn, this increasestravelling comfort and reduces maintenance costs.

Advantages as a result of prefabrication

The high level of prefabrication means considerably

reduced construction times.

Prefabrication also allows a high level of mechani-

sation to be used and facilitates quality assurance.

Advantages during maintenance and renovation

Reduction in downtimes due to improved renovation

and extension facilities.

The system also provides excellent repair and

maintenance conditions in the event of damage.

For converting existing routes, the neighbouring

track can continue to be used whilst the work is

being carried out.

Sagging is minimized by using drilled piles with

adjusted dimensions.

Ecological advantages

No sealing of the foundation soil takes place.

The existing soil structure (ground water) is not

altered by the drilled piles.

If necessary the appropriate modifications can be

made to the longitudinal bearer units to reduce

noise emissions.

The NFF System provides a whole host of advantages.

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09/2012e

ThyssenKrupp GfT Gleistechnik GmbH

Hollestr. 7a 45127 Essen Germany

Phone +49 201 844-563710 Fax +49 201 844-563714

www.tkgftgleistechnik.de [email protected]

SALES

Regional office

NorthVahrenwalder Str. 20530165 Hannover GermanyPhone:+49 511 6703-25Fax: +49 511 6703-37

WestHollestr. 7a

45127 Essen GermanyPhone: +49 201 844-563745Fax: +49 201 844-563750

EastRotherstr. 710245 Berlin GermanyPhone:+49 30 628901-15Fax: +49 30 628901-20/-21

SouthFrstenrieder Str. 26781377 Mnchen GermanyPhone:+49 89 7871-300Fax: +49 89 7871-343

South-West

Weilimdorfer Str. 74/ 270839 Gerlingen GermanyPhone: +49 7156 430730Fax: +49 7156 430740

EXPORT SALES

ExportHollestr. 7a45127 Essen GermanyPhone: +49 201 844-563764Fax: +49 201 844-563757

MANUFACTURING PLANT

HolzschwellenwerkAm Bahnhof 229393 Gro Oesingen GermanyPhone:+49 5838 9905-0Fax: +49 5838 9905-79

Location of sales

Waidmannstr. 2622769 Hamburg GermanyPhone:+49 40 85340-700Fax: +49 40 85340-701

An der Kreuzkirche 601067 Dresden GermanyPhone:+49 351 4902040Fax: +49 351 4902480

Dortmunder Str. 268219 Mannheim GermanyPhone:+49 621 8906-120/-121Fax: +49 621 8906-122

MRT Track &Services Co., Inc.270 Broad Street07003 Bloomfield NJ-USAPhone:+1 973 748-8899Fax: +1 973 748-9243

ThyssenKrupp WeichenbauObere Stahlindustrie 444793 Bochum GermanyPhone:+49 234 9114-343Fax: +49 234 9114-557

Humboldtstr. 304105 Leipzig GermanyPhone: +49 341 6017054Fax: +49 341 6017055

ThyssenKrupp

GfT Polska Sp. z o.o.

Al. Slowackiego 6630-004 Krakw PolandPhone: +48 12 6204130Fax: +48 12 2677548

Betrieb IndustrieweichenAm Wasserturm 3b06869 Coswig/Anhalt GermanyPhone: +49 34903 4741-0Fax: +49 34903 4741-20

VertriebsbereichWaggonausrstungRotherstr. 710245 Berlin GermanyPhone:+49 30 628901-15Fax: +49 30 628901-22

Betrieb SpannmittelAm Wasserturm 3b06869 Coswig/Anhalt GermanyPhone:+49 34903 4741-0Fax: +49 34903 4741-24

ThyssenKrupp LangschienenLadestr. 839175 Knigsborn GermanyPhone:+49 39292 6958-17Fax: +49 39292 6958-20

slab track nff system

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